SZYMON WOJCIK FLIGHTORY MOOSE (01) PDF MANUAL

The fuselage is available in two versions: with TPU-printed landing skids underneath, which help absorb impacts during landings in rough terrain, or without skids. All fuselage segment files that apply to the version with skids are appropriately labeled. Make sure to choose the correct version for your needs before printing.

The fuselage is divided into suggested compartments, each designed to optimally house specific equipment.

Battery Compartment:

Height: 90 mm

Length: 225 mm

Width: varies from 120 mm to 60 mm – the compartment narrows towards the nose of the fuselage.

Payload Compartment (Mapping Camera and Other Payload):

Height: 90 mm

Length: 140 mm

Width: 118 mm

Electronics Compartment (Flight Controller and Other Electronics):

Height: 50 mm

Length: 200 mm

Width: 100 mm

There are multiple options for selecting the powertrain configuration, including the motor, propeller, and battery. Recommended motors are in the 28XX class, with propellers ranging from 9 to 10 inches, and batteries rated from 4S to 6S. The MOTOR MOUNT uses a 19×19 mm bolt pattern, which matches the recommended motor size. This component is also provided in STEP format for easy modification if a different bolt pattern is required.

EXAMPLE MOTOR AND PROP SETUP

A recommended motor for this aircraft is the BrotherHobby Avenger 2812 V5 910KV, which performs optimally with 9453 tri-blade or two-blade propellers and a 6S battery. According to the manufacturer’s specifications, this setup delivers up to approximately 3800 g of thrust per motor at a maximum power of 1280W with a current draw of around 50A. This requires using an ESC rated at 60A (6S capable).

Yes, while the 6S configuration allows the motors to deliver maximum thrust and performance, the same setup can be operated very effectively with a 4S battery, offering a more efficient and lighter alternative without compromising flight capabilities. In this case, it is recommended to use a slightly larger propeller, such as a 10×6 two-blade, to compensate for the lower RPM resulting from the reduced voltage. This results in proportionally lower motor speed and a significantly reduced current draw, which allows for the use of smaller and lighter ESCs rated at 35-40A for 4S. At the same time, the overall system weight decreases, providing the option to use larger capacity 4S batteries. Despite the lower voltage, the total thrust generated by two motors remains around 4000 grams, which is fully sufficient for this aircraft’s design and operational requirements.

Prototype testing confirmed that during cruise flight with a 4S battery and 10×6 propellers, the required throttle setting was below 50%, demonstrating efficient power utilization and good endurance potential.

This flexible approach allows users to tailor the system to their needs. Whenever the mission demands higher thrust, greater payload, or higher airspeed, the same airframe can be seamlessly scaled by switching to 6S batteries and appropriate ESCs, immediately unlocking the full performance potential of the motors without requiring any changes to the mechanical setup.

This aircraft is designed with optimization for LW-PLA / LW-ASA filaments, reinforced with additional components printed from PC, PETG, or other rigid materials. All parts are designed to fit within a print volume of 220x220x200 mm. The entire design is tailored for printers equipped with 0.4 mm nozzles.

GENERAL GUIDLINES

– All airframe components should be printed using lightweight filaments (LW-PLA, LW-ASA) with single-wall construction.

– Fuselage sections: Recommended to print with gyroid infill between 3% and 6%.

– Wings: Use 2D Lattice infill, or optionally Cubic Subdivision, with an infill density between 3% and 4%.This approach ensures an optimal balance between strength and low weight while allowing flexibility for tuning print settings.

– For reinforcement parts that require higher strength, it is essential to use rigid and durable materials such as PETG, PC, ABS, or others. These components should be printed using the default print settings for the selected material and the standard strength profiles available in your slicer, ensuring reliable performance without the need for extra configurations.

– All airframe parts are designed to be printed without supports and with a single wall. (This applies to LW components; reinforcement parts can have a higher wall count.) Some files include pre-designed supports, which is indicated in the file name.

– Some components may benefit from adding supports touching the build plate, or increased wall count for improved strength in specific areas. These exceptions are clearly marked and explained in the Parts Orientation section.

Printing results may vary depending on several factors, such as the printer model, filament brand, filament moisture levels, ambient conditions like temperature and humidity, as well as whether the printer is equipped with an enclosed chamber. These variables can influence print quality, strength, and weight. Because of this, achieving optimal results often requires fine-tuning key parameters, particularly printing temperature, flow rate, and retraction settings. In most cases, only minor adjustments are necessary to reach excellent quality. It is strongly recommended to perform test prints when changing filaments, switching printers, or printing in different environmental conditions, in order to refine the settings for the best possible outcome.

The package includes WING1 MODIFIER and WING2 MODIFIER files in STEP format, which contain an additional solid in the motor mount area. This prepared file can be opened and sliced directly in the slicer by setting the additional solid as a modifier. This allows you to apply different print settings, such as increasing the number of walls to 2-3 and the infill density to 5-10%. These changes will only affect the overlapping volume between the wing and the modifier solid.

This method significantly strengthens the motor mount area, where higher forces are applied. You can also create your own modifiers directly in the slicer or in any CAD software and plan additional reinforcements if needed for your specific use case. This ready-made solution is provided in the package and can be used directly in the slicer.

All files are available in STL format. In addition, some important elements are available in STEP format, which allows easier editing and customization. You can find these files in folders labeled STEP.

1. The fuselage segments are designed with small 2 mm holes for alignment pins. The best option for this is to use short pieces of filament as pins. Before gluing, it is recommended to clean the parts and remove any supports.

2. Fit all fuselage segments together with the alignment pins in place (depending on whether the version with or without skids has been selected), then glue them using thick or medium CA adhesive.

3. Prepare the FUS and TAIL ROOT parts. Glue them in the designated places. These components reinforce the joint areas where the wings and stabilizers connect to the fuselage.

4. Prepare the FRONT REINFORCEMENT. Press M3 THREADED INSERTS into the designated holes, preferably using a slightly heated soldering iron. Once prepared, glue this part onto the front section of the fuselage.

5. Prepare the BATTERY PAD. This part serves as the battery mounting base. Glue it in place. The designed holes can be used to route velcro ties for securing the battery.

6. Prepare the FC PAD. This part serves as a mounting platform for the flight controller and other equipment. Glue the part into its designated place inside the fuselage. Using the FC PAD is optional.

7. Glue the front and middle hatch sections (HATCH FRONT 1, HATCH FRONT 2, MIDDLE HATCH 1, MIDDLE HATCH 2) together. Use alignment pins made from short pieces of filament.

8. Assemble the lock, which consists of three parts (LOCK 1, 2, 3). Glue the completed locks into the designated slots in the hatches. A thin layer of CA glue applied from the outside along the joint line is sufficient after the parts are properly fitted.

9. Fit the prepared hatches to the fuselage and make sure that the locks work properly and securely hold the hatches in place.

10. Prepare the nose and attach it to the fuselage using M3x6mm screws. The nose is designed by default to fit standard 19x19mm FPV cameras, with a shelf for a VTX.

11. If you have chosen the fuselage version with skids, prepare the skid parts printed from TPU and assemble them by gluing them together, using short pieces of filament as alignment pins. Once assembled, glue the skids into the designated slots on the bottom of the fuselage.

1. Prepare the wing segments (WING 1, WING 2, WING 3) along with the carbon fiber tubes with diameters of 6mm and 3mm, each with a length of 500mm. The 6mm tube acts as additional reinforcement along the leading edge, while the 3mm rod serves as the aileron hinge and reinforcement near the trailing edge. Insert the tubes into their dedicated slots and glue the wing segments together.

2. Once the wing is assembled, take the WING ROOT and glue it into the designated location, ensuring it is properly aligned.

3. Prepare the aileron segments (AIL 1, AIL 2) and glue them together using an alignment pin. Once the aileron is assembled, place it into its designated position on the wing and insert the 3mm carbon tube into the dedicated slot to form the hinge.

4. Take the WINGTIP and glue it onto the wing by sliding it over the exposed ends of the carbon tubes.

5. Take the SERVO PLATE WING and insert M3 threaded inserts. Prepare the micro servo and mount it. Secure with screws and optionally a small amount of hot glue. Attach the servo horn and center it.

6. Glue the prepared servo plate assembly into the designated position in the wing, routing the servo wires through the channel to the wing root. Secure the WING SERVO COVER using M3x6mm screws. Install the control horn and connect it to the servo horn with a pushrod.

7. Prepare the MOTOR MOUNT. Press the M3 threaded inserts into the top and bottom holes. Assemble the motor (e.g., 28XX) and attach it to the motor mount. Insert the assembled unit into the designated position in the wing and secure it with M3x10mm screws from both the top and bottom. The motor’s tilt angle is built into this design, so be sure to mount everything straight.

8. Insert the motor wires into the opening at the bottom of the wing and route them through the channel to the exit at the wing root.

9. Assemble the wing locks. The locks consist of the WING LOCK BASE and the top part WING LOCK. You will need a pin and a small torsion spring (pins and springs from small hair clips are a proven solution). The WING LOCK parts are marked (e.g., WLR for Wing Left Rear).

10. Glue the finished locks into their designated slots in the wing. Position the lock base so that it is perfectly flush with the surface of the wing root. The locks can be glued with CA glue or epoxy.

11. The second wing is assembled in the same way.

1. Prepare the V-Tail segments (VTAIL 1, VTAIL 2), the V TAIL ROOT, and an 8mm carbon tube cut to a length of 285mm. Assemble all the parts together with the tube inserted into its designated slot to help with alignment during gluing.

2. Take the ruddervator parts (RUDDER 1, RUDDER 2) and assemble them together. Place the completed part in its designated position and insert a 3mm carbon tube cut to 270mm, which acts as the control surface hinge.

3. Take the last V-tail segment (VTAIL 3) and glue it in place by sliding it onto the exposed end of the carbon tube at the tip of the stabilizer.

4. Prepare the SERVO PLATE V TAIL. Press M3 THREADED INSERTS into the designated holes, and glue the assembled parts into the recess in the tail.

5. Take the VTAIL SERVO COVER and mount a micro servo to it. Secure with screws and optionally hot glue. Route the servo cable through the channel to the outside. Attach the servo horn and center it. Attach the assembled part using M3x6mm screws.

6. Assemble the V-tail locks. They consist of the VTAIL LOCK BASE and the top part VTAIL LOCK. You will need a pin and a small torsion spring. The VTAIL LOCK parts are marked (e.g., VLR for V-Tail Left Rear).

7. Glue the finished locks into their designated slots in the stabilizer. Position the lock base to be flush with the surface of the root. Use CA glue or epoxy.

8. The second stabilizer is assembled in the same way.

This is an optional step if you want to use connectors to carry motor wires, servo cables, and other connections. It is also possible to skip it and manually connect/disconnect cables.

For Wing Connectors (Fuselage Side):

1. Prepare the WING CONNECTOR BASE. Press M3 THREADED INSERTS into the designated holes.

2. Glue the prepared part into the dedicated slot in the fuselage.

3. Take the WING CONNECTOR MR60 MALE along with the MR60 male plug. Solder it to the ESC wires.

For Wing Connectors (Wing Side):

1. Prepare the WING CONNECTOR BASE. Press M3 THREADED INSERTS into the designated holes and glue the part into the dedicated slot in the wing.

2. Prepare the WING CONNECTOR MR60 FEMALE and the MR60 connector. Solder the motor wires to it.

3. Attach the connector to the wing using M3x6mm screws. The connector is designed to fit an MR60 plug and includes a hole for standard servo connectors.

For V-Tail Connectors (Fuselage and Stabilizer):

The process is identical to the wing connectors but uses the VTAIL CONNECTOR BASE and VTAIL CONNECTOR MR30 MALE/FEMALE parts. The MR30 connector is used for the servo wires.

1. Prepare a 6mm carbon tube cut to a length of 130mm, which serves as the second spar for the stabilizer. Insert it into its designated slot on the tail when mounting the V-tail stabilizers.

2. Take the 10mm and 8mm carbon tubes, each 1000mm long, which serve as the main wing spars. Insert them into the designated slots in the fuselage.

3. Slide the wings onto the spars and push them firmly against the fuselage, securing them in their final position with the locks.

At this stage, the entire airframe is ready for installing and arranging the remaining electronics. Before the first flight, make sure that:

1. All control surfaces move in the correct directions.

2. The propellers rotate properly (one CW and the other CCW – according to the selected propellers in order to balance the prop torque).

3. The center of gravity is correctly set.

A diagram illustrates an example wiring and equipment layout, including suggested channel assignments for the servos and motors. The presented schematic is not the only solution but is intended to help beginners understand the setup. Optional components, such as the FPV camera, VTX, receiver, and additional sensors, are not included. This diagram is also available in a larger size in the file package.

Suggested Channel Assignments:

S1: Aileron Left

S2: Aileron Right

S3: V-Tail Left

S4: V-Tail Right

S5: Motor (ESC Right)

S6: Motor (ESC Left)

Throttle outputs are connected to the left and right motors.

A document with a preconfigured .param file may be available for guidance. The document outlines the key parameter settings of a .param file for ArduPilot, which can serve as a foundation for further configuration and tuning. The file may pertain to the Speedybee F405 Wing flight controller used with an ELRS receiver, GPS, and Walksnail FPV. This is not a ready-to-use configuration and should not be implemented without proper verification. Before flying, you must perform the following:

1. Configure the appropriate servo outputs for your aircraft’s setup.

2. Perform the necessary compass and accelerometer calibrations.

It is also recommended to review the user manual of the flight controller for configuration.